Apparatus and methods for automated picking of items

ABSTRACT

An automation apparatus for dispensing groups of individually packaged products, the apparatus including a storage arrangement adapted to store a plurality of products each contained in an individual package. The storage arrangement includes a first module and a second module, where the first module is adapted to store products having a first frequency demand threshold and the second module is adapted to store products having a second frequency demand threshold that is lower than the first frequency demand threshold. The apparatus further includes a plurality of fixed first discharge assemblies adapted to move selected ones of the individual packages from the first module of the storage arrangement and a second discharge assembly comprising a moveable pick device adapted to move selected ones of the individual packages out of the second module of the storage arrangement.

This Application is a Continuation of U.S. application Ser. No.16/984,986, filed Aug. 4, 2020, allowed, which is a Continuation of U.S.application Ser. No. 15/893,066 filed Feb. 9, 2018, patented, which is aContinuation of U.S. application Ser. No. 14/859,778, filed Sep. 21,2015, patented, which is a continuation of U.S. application Ser. No.12/559,601 filed Sep. 15, 2009, patented, and claims priority to U.S.Provisional Patent Application Ser. No. 61/120,209, filed Dec. 5, 2008,and the entire content of each is hereby incorporated by reference intheir entirety.

TECHNICAL FIELD

The present invention relates generally to a device for the picking ofstored items, and more particularly to a system for automaticallypicking medications, supplements, or other items to fill orders.

BACKGROUND

Hospitals, long term care and other health care facilities distributeand administer pharmaceutical products to patients in individual dosesnumerous times per day. Pharmaceutical products such as prescriptionmedications, nutritional supplements and the like are often stored inbulk by pharmacies and are repackaged into containers of multiple dosesbased on individual prescriptions for retail or outpatient distribution.For inpatient or in-facility distribution, pharmacies also oftenrepackage bulk pharmaceuticals into “unit of use” or “unit dose”packages, for example, multiple blister packs that are connectedtogether in a strip that contain multiple single doses of thepharmaceutical product.

The traditional method for distributing individual dosage units ofpharmaceutical products to patients begins with the generation of apatient order by a physician for particular medications. The patientorder is delivered to the pharmacy. There, the process of interpretingthe patient order, pulling the specified medication or supplements fromthe drug storage areas, packaging the medication or supplements, andlabeling the package is routinely done manually by pharmacy supportpersonnel. After a final check by the facility pharmacist, the packagedindividual dosage units are ready for distribution. In large facilities,the packages containing the patient's order are forwarded to individualnursing units where nursing staffers distribute and administer them tothe patients.

There are several disadvantages associated with the traditional methodof distributing individual dosage units of pharmaceutical products. Tobegin with, the process is labor and cost intensive. Many separate laborsteps are required to fill a single patient order. In large facilitiesservicing hundreds of patients each day, the staffing requirements torapidly process patient orders are substantial. In addition, with somany human inputs required in the existing process, there may also be arisk of human error.

As an attempt to address at least some of the issues with respect tostaffing requirements and human error, a variety of automated medicationdispensing systems have been developed. The current landscape forautomated medication dispensing is dominated by a 30-day systemutilizing either “bingo cards” or unit doses supplied in a 30-day box.The known systems provide a 30-day or other multi-day supply for eachpatient pass-time for each prescription on a relatively long term basis.In the event the patient is discharged or the treatment is changed, theunused portion of the 30-day supply cannot be cost effectively reusedeven though the product may be labeled appropriately. The labor costrequired to reintroduce the pharmaceutical products into thedistribution system and to maintain the integrity and traceability ofmanufacturer and expiration data exceeds the value of the pharmaceuticalproducts, even if the substantial restocking fees are paid by thehealthcare system. As a result, such unused pharmaceutical products arereturned to the pharmacy for disposal. This disposal of unusedpharmaceutical products is a significant waste of those resources aswell as a detriment to the environment.

One known pharmaceutical package dispensing system automates variousaspects of the task of filling patient orders for units of usepharmaceuticals. The system employs a number of storage cartridgesarranged in stacked rows on a frame. The cartridges contain strips ofunit dose packages of pharmaceutical products. The packages consist ofindividual unit dose blisters. Each of the blisters contains a unit ofuse, e.g., a single tablet or capsule. Several blister packages arejoined together to form the linear strips such that a given cartridgemay contain several such strips stacked vertically or in roll form. Eachcartridge is provided with a forward-facing opening through which aportion of the lowermost blister strip contained therein projects. Apick head is movable adjacent a respective row of cartridges to adesired location adjacent a cartridge. The pick head pulls the blisterstrip out of the cartridge and a cutting blade mounted on the pick headcuts an individual blister from the strip. The severed blister packfree-falls onto a conveyor or into a bin on the pick head or elsewhereand when the pick head has finished picking blisters for the order, itdischarges the blisters in the bin onto a tray. The tray serves as anaccumulation point servicing multiple pick heads. The tray is moved to adischarge location to dump the blisters by gravity from the tray into afunnel of a packaging station.

The drug dispensing machine described above and similar such systemshave several disadvantages. To begin with, only one tray and dischargeslide for the multiple pick heads is provided. Therefore, a pick headmay have to wait for a tray to empty, which significantly reduces thepicking efficiency of the pick heads and throughput of the dispensingmachine. Second, the cartridge, pick head and bin design can lead todifficulties when a given blister strip is pulled, cut and dropped fromthe cartridge. The opening through which the blister strips projectallows for significant lateral play by the strips . Further, the size ofthe unit doses may vary greatly and pick head retrieval and cuttingmechanisms must be adjusted to accommodate unit doses of differentsizes. This can lead to misalignments with the cutting blade. Thegravity free-fall of the severed unit doses often results in missing orjammed unit doses producing incomplete orders and requiring manualintervention to dislodge, retrieve and/or collect the errant unit doses.

There is a continuing need to improve a system and overall methodologyfor dispensing medication orders for individual patients in health carefacilities.

SUMMARY

The present invention overcomes the foregoing and other shortcomings anddrawbacks of dispensing systems heretofore known for use in fillingorders for medications and/or supplements. While the invention will bedescribed in connection with certain embodiments, it will be understoodthat the invention is not limited to these embodiments. On the contrary,the invention includes all alternatives, modifications and equivalentsas may be included within the spirit and scope of the present invention.

According to one aspect of the present invention, a system forassembling and dispensing an order made up of one or more individuallypackaged items from a plurality of different individually packaged itemsincludes a storage module containing one or more packages of each of theitems, and a conveyor having selectively assignable spaces configured toreceive the packaged items associated with a particular order and totransport the packaged items to a processing location. The systemfurther includes a pick device that is movable relative to the storagemodule and configured to retrieve a package from the storage module. Atransfer station adjacent the conveyor receives one or more of thepackaged items from the pick device and an actuator associated with thetransfer station moves the packaged items from the transfer station tothe conveyor when the assigned space associated with the order is inregistration with the transfer station.

In another aspect, the system further includes a transfer nest that ismovable with the pick device and which receives the packaged items fromthe pick device and transfers the packaged items to the transferstation. The transfer nest and/or the transfer station may have slots orchannels that are shaped complimentary to the shape of the packagescontaining the items such that the packages are constrained for movementonly along longitudinal directions of the slots or channels. Movement ofthe packages between the storage module and the processing location ispositively controlled and the packages are not permitted to move in anunconstrained manner.

In another aspect, a method of filling an order that includes one ormore individually packaged items selected from a plurality of differentindividually packaged items includes assigning a dedicated space on aconveyor for receiving one or more of the packaged items, moving theconveyor toward a processing location, picking a packaged item from astorage location, moving the item to a transfer station, and moving theitem from the transfer station to the dedicated space on the conveyorwhen the dedicated space is in registration with the transfer station.

The above and other objects and advantages of the present inventionshall be made apparent from the accompanying drawings and thedescription thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary system for storing anddispensing medications and supplements in accordance with the presentdisclosure.

FIG. 2 is a perspective view of an exemplary package for containing asingle dose of a medication/supplement in accordance with the presentdisclosure.

FIG. 3 is a perspective view of an exemplary carrier of a conveyor inaccordance with the present disclosure.

FIG. 3A is an end elevation view of the carrier of FIG. 3 .

FIG. 4 is an enlarged perspective view of the storage module, conveyor,gantry, and pick device of FIG. 1 .

FIG. 5 is an enlarged perspective view of a portion of the storagemodule of FIG. 4 .

FIG. 6 is a partial exploded view of the storage module of FIG. 5 .

FIG. 7 is an enlarged perspective view of the storage module depicted inFIG. 6 .

FIG. 8 is a perspective view depicting the pick device and transferstation of the low-demand module of the dispensing system.

FIG. 9 is an enlarged perspective view of the pick device of FIG. 8 .

FIG. 9A is a partial detail view along line 9A-9A of FIG. 16 .

FIG. 10A is a partial cross-sectional view depicting the pick device andtransfer nest taken generally along line 10A-10A of FIG. 9 .

FIG. 10B is an enlarged cross-sectional detail view of FIG. 10A,illustrating a gripper and a storage tube.

FIG. 11 is a partial cross-sectional view, similar to FIG. 10A, anddepicting a vacuum manifold of the pick device.

FIG. 12A is a partial cross-sectional view, similar to FIG. 10A, anddepicting the rotating cam in a second position wherein a gripper isextended to engage a package.

FIG. 12B is an enlarged detail view of the gripper and storage tube ofFIG. 12A.

FIG. 12C is a partial cross-sectional view, similar to FIG. 12A, anddepicting the vacuum manifold.

FIG. 12D is a partial cross-sectional view, similar to FIG. 12A, anddepicting an indexing mechanism of the pick device.

FIG. 13A is a partial cross-sectional view, similar to FIG. 12D, whereinthe grippers have been indexed to the next position.

FIG. 13B is a partial cross-sectional view, similar to FIG. 13A, whereinthe grippers have been retracted by the cam.

FIG. 13C is a partial cross-sectional top view, similar to FIG. 13B,illustrating the vacuum applied to the grippers.

FIG. 14A is a partial cross-sectional view, similar to FIG. 13B, whereinthe grippers are indexed to a successive position.

FIG. 14B is a partial cross-sectional view, similar to FIG. 14A,depicting the grippers extended and retracted by the cam.

FIG. 14C is a partial cross-sectional view, similar to FIG. 14B,illustrating the vacuum pressure applied to the grippers.

FIG. 15 is a partial cross-sectional view, similar to FIG. 14B,depicting the grippers of the pick device indexed to the next position.

FIG. 16 is a partial cross-sectional view depicting the transfer ofpackages from the transfer nest to the transfer station.

FIG. 17 is a partial cross-sectional view, similar to FIG. 16 ,depicting the packages in the queue support of the transfer station.

FIG. 18 is a partial cross-sectional view, similar to FIG. 17 ,depicting the packages transferred between the queue support and acarrier on the conveyor.

DETAILED DESCRIPTION

FIG. 1 depicts an exemplary automated dispensing system 10 in accordancewith the principles of the present disclosure. In the embodiment shown,the dispensing system 10 is configured to store and dispenseindividually packaged and labeled doses of medications/supplements, andto assemble the dispensed medications/supplements into individualmedication orders, such as time-pass medication orders to be deliveredto a long-term care facility, for example. It will be appreciated,however, that a dispensing system in accordance with the presentdisclosure may alternatively be configured to dispense other items. Thedispensing system 10 is divided into distinct modules that are dedicatedto dispensing the medications/supplements based on the demand, or orderfrequency, of those items. In the embodiment shown, a first module 12 isconfigured to dispense medications/supplements having a relatively highdemand or order frequency, and a second module 14 of the dispensingsystem 10 is configured to store and dispense medications/supplementshaving a relatively lower demand or order frequency.

In the embodiment shown and described herein, themedications/supplements are provided in packages 16 sized to receive anindividual dose of a particular medication/supplement, commonly referredto as a blister pack. With reference to FIG. 2 , an exemplary package 16comprises a base portion 18 defining a cavity for receiving theindividual dose of the medication/supplement 20, and a generally planarclosure 22 disposed over an open end of the base portion 18. Thepackages 16 may be provided with information 24 related to themedication/supplement 20 contained in the packages 16, such as the nameof the medication/supplement 20, the manufacturer, the datemanufactured, the lot number, and/or other information. In theembodiment shown, information 24 is provided on the closure 22 andincludes machine-readable information, such as a bar-code, that may beused to facilitate the automated storing, tracking, dispensing, andpackaging of orders.

With continued reference to FIG. 1 , the dispensing system 10 furtherincludes an endless conveyor 30 comprising a plurality of carriers 32that move past the first, high-demand module 12 and the second,low-demand module 14 to collect ordered medications/supplements andcarry them to a designated location for further processing. In theembodiment shown, a first end 34 of the conveyor 30 is positionedadjacent the high-demand module 12. The carriers 32 are moved along theconveyor 30 past the high-demand module 12 and the low-demand module 14toward a second end 36 where the medications/supplements are packagedfor delivery to a long term care facility. In the embodiment shown inFIG. 1 , the conveyor 30 comprises a pair of oppositely disposed,longitudinally extending rails 38 a, 38 b supporting the plurality ofcarriers 32. The conveyor 30 may further comprise cross-members 40extending between the rails 38 a, 38 b and support legs 42 configured tosupport the longitudinally extending rails 38 a, 38 b a distance above afloor surface.

FIGS. 3 and 3A depict an exemplary carrier 32 comprising an elongate,generally rectangular body 50 having a longitudinal channel 52 formedinto one side and extending between the ends of the body 50. The channel52 is shaped complementarily to the shape of the packages 16 andincludes a deep central portion 54 and shallower side portions 56 a, 56b disposed on opposite sides of the central portion 54, whereby apackage 16 can be received in the channel 52 with the base 18 positionedin the central portion 54 and the sides of the closure 22 supported onthe side portions 56 a, 56 b. The side portions 56 a, 56 b are enclosedat their upper ends, such as by top plates 58 or other structure so thatpackages 16 received in the channel 52 are constrained for movement onlyalong a longitudinal direction of the channel 52. The focus of thisdisclosure is the low-demand module 14 of the dispensing system,depicted in more detail in FIG. 4 and discussed below.

Referring now to FIG. 4 , the low-demand module 14 comprises a storagemodule 60 for storing the individually packaged and labeledmedications/supplements, a pick device 62 for retrieving selectedmedications/supplements from the storage module 60, and a transferstation 64 for delivering the selected medications/supplements to thecarriers 32 of the conveyor 30 to fill orders. The storage module 60comprises one or more storage units 66 positioned alongside the conveyor30, as may be desired, to accommodate storage of themedications/supplements needed to fill the medical orders. Withcontinued reference to FIG. 4 , and referring further to FIGS. 5-7 ,each storage unit 66 comprises a plurality of generally rectangular,vertically-spaced plates 68 and a plurality of laterally spaced walls 70disposed between each plate 68 to define an array of elongate bins 72configured to receive storage tubes 74 containing stacked packages 16 ofthe individually packaged medications/supplements. The storage tubes 74are slidably received in the respective bins 72 at first, receiving ends76 of the bins 74.

In the embodiment shown, the plates 68 and walls 70 of the storage unit66 are formed from aluminum sheet material. The walls 70 are formed withnotches 78 and tabs 80, and the plates 68 are formed with correspondingslots (not shown) whereby the walls 70 and plates 68 may be assembledtogether to form the array of bins 72. In the embodiment shown, the bins72 have a generally rectangular cross-sectional shape, as do the storagetubes 74 that are received within the respective bins 72. In thisembodiment, the tubes 74 are formed from extruded plastic material andan end cap 82 disposed at one end of the tube 74 facilitates dispensingthe packages 16 therefrom. As shown in FIG. 7 , the end cap 82 includesa slot 84 along an upwardly facing side of the storage tube 74 wherebyan individual package 16 may be moved in a direction transverse to thelongitudinal axis of the storage tube 74 for removal of the package 16from the storage tube 74 through the slot 84. With continued referenceto FIG. 7 , each bin 72 is provided with a registration pin 90 proximatea second, dispensing end 92 that faces the pick device 62. As thestorage tubes 74 are placed within the respective bins 72, theregistration pins 90 engage another slot 94 formed on the end cap 82 toposition the end cap 82 at a location that facilitates engagement andretrieval of the individual packages 16 stored in the tube 74 by thepick device 62, as will be described in more detail below.

As depicted in FIG. 5 , each storage unit 66 is supported on a base 100so that storage tubes 74 supported in the bins 72 of the storage unit 66may be positioned for proper access by the pick device 62. The base 100comprises a generally flat plate 102 that may be bolted or otherwisesecured to the floor surface. The array of bins 72 may be pivotallycoupled to the plate 102 by appropriate pin connections 104, 106, andmay be adjusted to have a desired inclination angle relative to thefloor surface by an adjustable link 108 coupled between the array ofbins 72 and the plate 102. The inclined orientation of the bins 72 ofthe storage unit 66 places the dispensing ends 92 of the bins 72 at alower elevation than the receiving ends 76.

The packages 16 of medications/supplements are stacked one atop anotherwithin the storage tubes 74, and the storage tubes 74 are slidablyreceived within the respective bins 72 of the storage unit 66. Thestorage tubes 74 are inserted with the end caps 82 positioned at thedispensing ends 92 of the bins 72 such that the stacked packages 16within the tubes 74 are urged by gravity in a direction toward the endcaps 82 at the dispensing ends 92 of the bins 72. A weight (not shown)may be provided on top of the uppermost package 16 within each storagetube 74 to facilitate movement of the packages 16 toward the end caps82. As depicted in FIG. 10B, each bin 72 may be provided with a sensor97 proximate the dispensing end 92 for detecting the presence ofpackages 16 within the storage tube 74 supported in the bin 72, and forcommunicating with a control 240 to indicate when the storage tube 74needs to be replaced with a storage tube 74 filled with packages 16. Thebins 72 may also be provided with one or more sensors 99 for detectingthe presence of a storage tube 74 in the bin, and for communicating withthe control 240 when a storage tube 74 is not in the bin 72. In theembodiment shown, in FIGS. 10B and 12B, sensors 97 for detecting thepressure of packages 16 in a storage tube 74 are located with theregistration pin 90.

Each storage tube 74 contains only a single type ofmedication/supplement, and the storage tubes 74 may be provided withinformation 96 identifying the particular type of medication/supplementcontained within the packages 16 stacked within the tube 74 (FIG. 7 ).In one embodiment, the information provided on the storage tubes 74includes machine readable information, such as bar codes, RFID, or othertypes of machine readable information, to facilitate the automatedstorage, tracking and dispensing of the medications/supplements.

The medications/supplements stored in the array of bins 72 of thestorage units 66 of the storage module 60 are retrieved by the pickdevice 62 and are delivered to a transfer station 64 for subsequenttransfer to a designated carrier 32 as the carrier 32 moves past thetransfer station 64 on the conveyor 30, as will be described in moredetail below . With reference to FIGS. 4 and 8 , the pick device 62comprises a pick head 110 and a transfer nest 112 supported on atransfer frame 114 that moves with the pick head 110. The pick device 62is supported on a vertically inclined gantry 116 having vertical framemembers 118 and horizontal frame members 120 positioned proximate thedispensing ends 92 of the bins 72 of the storage module 60 for access tothe storage tubes 74. A gantry crossmember 122 is driven by a firstmotor 124 for movement longitudinally along the horizontal frame members120, and a second drive motor 126 moves the pick device 62 verticallyalong the gantry crossmember 122 so that the pick head 110 can accessany of the plurality of storage tubes 74 housed in the storage module60. Flexible cable guides 128 a, 128 b may be provided adjacent thegantry crossmember 122 and/or the horizontal frame members 120 to housecables or wires extending between the pick device 62 and correspondingpower supplies and/or control modules.

As shown in FIGS. 9 and 10A, the pick head 110 comprises a plurality ofgrippers 130 extending from a rotatable housing 132 for engaging andretrieving selected packages 16 from the storage tubes 74 supported inthe storage module 60. Four grippers 130 a, 130 b, 130 c, 130 d aredepicted and are collectively referred to as “grippers 130” herein. Thetransfer nest 112 is supported within a transfer frame 114 coupled tothe pick head 110 for movement therewith, such that packages 16 selectedby the pick head 110 may be received onto the transfer nest 112 andsubsequently delivered to the transfer station 64. In the embodimentshown, the transfer nest 112 includes four slots 134 for receiving thepackages 16 of medications/supplements from the grippers 130 of the pickhead 110. It will be appreciated, however, that the transfer nest 112may alternatively have a fewer number or a greater number of slots 134,as may be desired. The slots 134 of the transfer nest 112 are configuredto receive the packages 16 from the grippers 130 of the pick head 110and to maintain positive control over the motion of the packages 16 asthey are moved to the transfer station 64. To this end, the slots 134are shaped complementarily to the shape of the packages 16, in a mannersimilar to the channels 52 of carriers 32 and as depicted in FIG. 9A.

The transfer nest 112 is movable along a shaft 140 in a longitudinaldirection relative to the pick head 110 so that the selected packages 16of medications/supplements may be received in one of the plurality ofslots 134 on the transfer nest 112 by aligning a selected slot 134 inregistration to receive a package 16 from the grippers 130 of the pickhead 110. The transfer nest 112 is also pivotable about a shaft 142coupled to the transfer frame 114 to position the transfer nest 112adjacent the transfer station 64 for delivery of the selected packages16 of medications/supplements to the transfer station 64. In theembodiment shown, the transfer nest 112 is pivotally coupled to thetransfer frame 114 by a shaft 142 received in shaft supports 144extending from the transfer frame 114. A bracket 146 extending from thetransfer nest 112 is coupled at a pivot joint 148 to the end of a driverod 150 of a pneumatic piston 152, whereby the transfer nest 112 can bepivoted around the shaft 142 by actuation of the pneumatic piston 152,from a first position wherein the transfer nest 112 is located adjacentthe pick head 110 for receiving the selected packages 16 ofmedications/supplements (depicted in FIGS. 8 and 9 ), to a secondposition wherein the transfer nest 112 is positioned adjacent thetransfer station 64 (depicted in FIG. 16 ).

Referring again to FIG. 8 , the transfer station 64 comprises a slideassembly 160 for moving the packages 16 of medications/supplements fromthe transfer nest 112, and a queue support 162 for receiving thepackages 16 of medications/supplements from the transfer nest 112 andsupporting them until the carrier 32 assigned to receive the packages 16of medications/supplements for a particular order is positioned at thequeue support 162 in registration for receiving the packages 16. Theslide assembly 160 comprises a plurality of individually actuatableslide members 164 having upwardly extendable prongs 166 that engage thepackages 16 of medications/supplements supported on the transfer nest112 when the transfer nest 112 has pivoted to the second position. Theprongs 166 slide the packages 16 of medications/supplements from thetransfer nest 112 into corresponding channels 168 formed in the queuesupport 162 of the transfer station 64. In the embodiment shown, thechannels 168 formed in the queue support 162 are shaped complementarilyto the shape of the packages 16 of medications/supplements, in a mannersimilar to the channels 52 of carriers 32, such that the packages 16received in the respective channels 168 of the queue support 162 areconstrained and allow for movement only along longitudinal directions ofthe channels 168.

With continued reference to FIG. 9 , and referring further to FIG. 10A,operation of the pick device 62 to retrieve selected packages 16 ofmedications/supplements from the storage tubes 74 supported in the arrayof bins 72 of the storage units 66 and to place the selected packages 16in the transfer nest 112 for subsequent transfer to the transfer station64 will now be described. The pick device 62 comprises a pick head 110having four grippers 130 disposed generally circumferentially around ahousing 132 of the pick head 110 and arranged such that pairs ofgrippers 130 a, 130 c and 130 b, 130 d are positioned on diametricallyopposite sides of the housing 132. Each gripper 130 comprises a gripperarm 170 slidably received in guides 172 coupled to the housing 132 tofacilitate movement of the gripper arms 170 along radial directionsrelative to the housing 132. Springs 174 coupled to the gripper arms 170and contacting the guides 172 bias the gripper arms 170 in directionsradially outwardly from the housing 132. The housing 132 of the pickhead 110 is rotatable to index the grippers 130 from positions adjacentthe storage tubes 74, for engaging and retrieving packages 16 ofmedications/supplements, to positions adjacent the transfer nest 112 forplacing the selected packages 16 into one or more slots 134 of thetransfer nest 112. As depicted in FIG. 12D, the pick head 110 of theembodiment shown is rotatably indexed by a Geneva drive mechanism 180for successive, intermittent positioning of the respective grippers 130adjacent the storage module 60 and the transfer nest 112. A driven wheel182 is rotatably supported on a central shaft 184 of the pick head 110and is driven for intermittent rotation by a drive wheel 186 supportedon a rotating drive shaft 188 spaced from the central shaft 184. As thedrive wheel 186 rotates, engagement rods 190 positioned on diametricallyopposed sides of the drive wheel 186 engage corresponding slots 192formed in the driven wheel 182 to rotate the driven wheel 182. Thedriven wheel 182 is coupled to an index plate 194, which is in turncoupled to the pick head housing 132, whereby intermittent rotationalmotion is imparted to the housing 132 to move the grippers 130.

The pick head 110 is also configured to move the gripper arms 170 alongdirections extending radially from the housing 132 to facilitateengaging the packages 16 of medications/supplements stored in thestorage tubes 74 and placing the selected packages 16 within slots 134on the transfer nest 112. Radial movement of the gripper arms 170 iscontrolled by a rotating cam plate 200 disposed within the pick headhousing 132. An aperture 202 formed in the cam plate 200 defines a camsurface 204 that engages follower pins 206 coupled to the proximal ends208 of the gripper arms 170. In the embodiment shown, the cam surface204 is configured to move one pair of diametrically opposed gripper arms170 radially outwardly (associated with grippers 130 b and 130 d, forexample) while the other oppositely disposed pair of gripper arms 170 ismoved radially inwardly (associated with grippers 130 a and 130 c, forexample). The inward/outward motion of the gripper arm pairs isalternated as the cam plate 200 rotates within the pick head housing132.

The distal end 210 of each gripper arm 170 includes a suction cup 212for applying vacuum pressure to the planar closure 22 of a package 16positioned adjacent the dispensing slot 84 of a storage tube 74. Thedistal end 210 of each gripper arm 170 may include a pin 214 forpositively engaging an edge of the closure 22 of the package 16 tofacilitate lifting the package 16 from the dispensing slot 84 of thestorage tube 74. However, the pin 214 may be eliminated to avoidpossible damage to the packages 16 during transfer to the slots 134.Vacuum pressure is supplied to the suction cups 212 by conduits 220 thatare operatively coupled to a vacuum manifold 222 disposed within thepick head housing 132 and to a vacuum passage 223 in the gripper arm170. As shown in more detail in FIG. 11 , the vacuum manifold 222comprises a vacuum passage 224 configured to provide vacuum pressure tothe suction cups 212 of the respective grippers 130 at appropriatepositions of the grippers 130 relative to the pick head housing 134 tofacilitate retaining the packages 16 on the distal ends 210 of thegripper arms 170 from the time that the packages 16 are retrieved fromthe storage tubes 74 until the packages 16 are placed in the slots 134of the transfer nest 112. To this end, the vacuum passage 224 comprisesa first portion 224 a that extends generally circumferentially around aportion of the pick head housing 132, and a second portion 224 bextending in a radial direction along the manifold 222 and communicatingwith an outlet port 226 coupled to a source of vacuum pressure.

With continued reference to FIGS. 10A and 10B, the retrieval of aselected package 16 from a storage tube 74 by the pick head 110 will nowbe described. In FIG. 10A, the pick head 110 has been moved to alocation relative to the storage module 60 to position a first gripper130 a adjacent a storage tube 74 supported in the storage module 60 andcontaining a plurality of packages 16 of a particularmedication/supplement required to fill an order. The distal end 210 ofthe first gripper arm 170 is spaced from the end cap 82 of the storagetube 74. With the first gripper 130 a positioned adjacent the storagetube 74, vacuum pressure is supplied to the suction cup 212 by thevacuum manifold 222. The cam plate 200 rotates to move the first gripperarm 170 in a direction toward the end cap 82 of the storage tube 74 suchthat the suction cup 212 engages the surface of the closure 22 of thelower-most package 16 in the storage tube 74, and the pin 214 engagesthe side edge of the package 16, as depicted in FIGS. 12A and 12B. Thevacuum pressure applied at the suction cup 212 draws the package 16firmly against the distal end 210 of the first gripper 130 a, and liftsthe package 16 through the dispensing slot 84 of the end cap 82 as theGeneva drive mechanism 180 is indexed to the next position, as depictedin FIGS. 12D and 13A.

Referring now to FIG. 13A, the selected package 16 is supported on thedistal end 210 of the first gripper 130 a adjacent a sensor 230configured to detect the presence of a package 16 on the first gripper130 a. The sensor 230 may also be configured to read machine readableinformation provided on the package 16. The sensor 230 can therefore beused to confirm that a package 16 was retrieved by the first gripper 130a and that the selected package 16 is the package 16 intended to beselected to fill the order. Indexing of the Geneva drive mechanism 180to move the first gripper 130 a and the package 16 supported thereonadjacent the sensor 230 also moves the second gripper 130 b into aposition for engaging and retrieving another package 16 from the storagetube 74, in the event that more than one dose of themedication/supplement is required to fill the order. If a differentmedication/supplement is required, the pick device 62 may be moved onthe gantry 116 to position the second gripper 130 b adjacent anappropriate storage tube 74 containing packages 16 of the desiredmedication/supplement.

The cam plate 200 then rotates to move the first gripper 130 asupporting the package 16 in a direction radially inwardly toward thepick head housing 132, while at the same time the second gripper 130 bis moved radially outwardly to engage a subsequent package 16 supportedin a respective storage tube 74 for retrieval of the package 16 asdescribed above. FIG. 13C depicts the vacuum manifold 222 andillustrates how vacuum pressure is maintained at the suction cup 212 ofthe first gripper 130 a adjacent the sensors 230.

Referring now to FIG. 14A, the Geneva drive mechanism 180 indexes thefirst gripper 130 a to a position adjacent the transfer nest 112, whilesimultaneously moving the second gripper 130 b (now supporting a package16) adjacent the sensor 230, and moving the third gripper 130 c adjacentthe storage module 60 to a position to retrieve a subsequent package 16from the same storage tube 74, or from a different storage tube 74, asmay be required. As the drive wheel 186 of the Geneva drive mechanism180 continues to rotate, the cam plate 200 rotates to move the firstgripper 130 a radially outwardly to position the package 16 inregistration with a selected slot 134 of the transfer nest 112, asdepicted in FIG. 14B. Simultaneously, the second gripper 130 b is movedin a direction radially inwardly, while the third gripper 130 c is movedradially outwardly to engage a subsequent package 16. FIG. 14Cillustrates the vacuum manifold 222 with the first gripper 130 aadjacent the transfer nest 112 and shows how vacuum pressure is appliedto the suction cup 212 at this position. As the first gripper 130 a issubsequently indexed to the next position, vacuum pressure appliedthrough the first portion 224 a of the vacuum passage 224 is shut off tothe conduit 220, and the package 16 is released into the slot 134 on thetransfer nest 112, as illustrated in FIG. 15 , which depicts the pickhead 110 indexed to the next successive position by the Geneva drivemechanism 180, whereby the second gripper 130 b is in position to placea package 16 supported on the second gripper 130 b onto the transfernest 112. After the last package 16 in an order is picked, the Gantry116 moves the pick device 62 to a location between the storage units 66,where there are no storage tubes 74. Since there are no packages 16present, the pick device 62 can advance two positions therebytransferring the packages already supported by the remaining twogrippers 130 into the slot 134 of the transfer nest 112 withoutacquiring additional packages 16, completing the order.

After the packages 16 of medications/supplements associated with one ormore orders are placed on the transfer nest 112, the pick device 62 ismoved by the gantry 116 to a position adjacent the transfer station 64.The pneumatic cylinder 152 is then actuated to pivot the transfer nest112 from the first position adjacent the pick head 110 to the secondposition adjacent the slide assembly 160 of the transfer station 64, asdepicted in FIG. 16 . With the transfer nest 112 in the second position,one or more of the slide members 164 may be actuated to push theselected packages 16 from the slots 134 on the transfer nest 112 intocorresponding channels 168 on the queue support 162 in registration withthe slots 134 of the transfer nest 112, as depicted in FIG. 17 . Thepackages 16 of medications/supplements supported in the queue support162 are held until the designated carrier 32 assigned to receive theparticular order associated with the medications/supplements is inposition adjacent the corresponding channel 168 of the queue support162. Thereafter, the prongs 166 of the slide member 164 are furtheractuated to push the corresponding packages 16 of medicationssupplements from the queue support 162 into the appropriate carrier 32on the conveyor 30, as depicted in FIG. 18 .

After the packages 16 of medications/supplements have been moved fromthe transfer nest 112 to the slide assembly 160, the transfer nest 112is pivoted from the second position back to the first position, adjacentthe pick head 110, and the pick device 62 is moved on the gantry 116 toa position adjacent a selected storage tube 74 for retrieval of apackage 16 required for the next order. The process described above isrepeated to assemble additional orders. After the packages 16 ofmedications/supplements for an order have been transferred from thequeue support 162 to the assigned carrier or carriers 32, the slidemembers 164 return to retracted positions as depicted in FIG. 16 toawait the delivery of the next batch of packages 16 from the pick device62. Having received all of the packages 16 of medications/supplementsrequired to fill the orders, the carriers 32 continue along the conveyor30 to a packaging station for subsequent processing into appropriatecontainers for delivery to the one or more long-term care facilities.

In the embodiment shown, the low-demand module 14 of the dispensingsystem 10 includes five individual transfer stations 64 configured toreceive packages 16 of medications/supplements for transfer torespectively assigned carriers 32 on the conveyor 30, as describedabove. it will be appreciated, however, that the dispensing system mayalternatively include fewer than five transfer stations 64, or greaterthan five transfer stations 64, as may be desired for the particularrequirements of the dispensing system 10. The provision of multipletransfer stations 64 enables the pick head 110 to preselect the packages16 of medications/supplements associated with a plurality of orders andtransfer the packages 16 into respective queue supports 162 toaccommodate substantially continuous operation of the conveyor 30. Inone embodiment, the conveyor 30 is configured to incrementally move thecarriers 32 from the first end 34 to the second end 36 such that acarrier 32 is indexed approximately every 3 seconds.

The dispensing system 10 further includes a control 240 configured toreceive orders for medications/supplements and to process the orders fordelivery to a long-term care facility. Orders may be electronicallyreceived by the control 240 from one or more long-term care facilities,such as by transmission over a network, or by any other suitable method.Alternatively, orders can be input directly into the control 240 via anappropriate interface, such as a keyboard or other suitable devices. Thecontrol 240 identifies which medications/supplements are required fromthe high-demand module 12 and the low-demand module 14 to fill eachorder. In one embodiment, the orders corresponding to each medicationpass to be administered to a particular patient for that particular dayare processed by the control 240 such that the packages 16 ofmedications/supplements for each medication pass to be administered tothe patient are assembled into a package, and the packages of medicationpasses are then grouped together for delivery to the long-term carefacility.

The control 240 assigns one or more carriers 32 to receive the packages16 of medications/supplements for each order. The control 240 thencontrols the movement of the carriers 32 on conveyor 30 through thehigh-demand module 12 and the low-demand module 14 to receive thepackages 16 as described above and in related U.S. patent applicationSer. No. 12/559,630 (Attorney Docket 387209US), filed on even dateherewith and incorporated herein in its entirety. The control 240controls operation of the low-demand module 14 to retrieve the packages16 of medications/supplements for the orders ahead of the arrival of thecarriers 32 assigned to the orders and while the carriers 32 arereceiving the ordered medications/supplements from the high-demandmodule 12 as the carriers 32 are moved past the high-demand module 12.The transfer nests 64 provide a buffer to accumulate themedications/supplements in advance of the arrival of the carrier 32 forthe specific order. The control 240 is coupled to an order entrydatabase and via a web service the orders are passed to the dispenser 10one at a time. Alternatively, multiple orders may be passed at a time,for example, ten orders passed at a time. As such, the remaining,subsequent orders are buffered in the database.

In another embodiment, the dispensing system 10 may be configured toreceive and process short turn-around time orders (“stat orders”) thatare received separately from the periodically received orders from thelong-term care facilities. The control 240 integrates the stat ordersinto the orders being processed and may direct the assembled stat orderto a separate location for subsequent handling.

The control 240 may also be configured to receive signals from varioussensors associated with the dispensing system 10 to facilitate managingoperation of the dispensing system 10. For example, in one embodiment,the control 240 is configured to receive signals from sensors 97, 99,230 of the low-demand module 14 related to the detection of packages 16in a storage tube 74, the presence of storage tubes 74 in a bin 72, andthe presence of a package 16 supported on a gripper 130, respectively.When the control 240 receives a signal from a sensor 97 indicating thatthe storage tube 74 associated with the sensor 97 is empty, control 240provides a signal to an operator indicating that the storage tube needsto be replaced or replenished. When control 240 receives a signal from asensor 99 indicating that a storage tube 74 is not detected in theassociated bin 72, the control may provide a signal to an operatorindicating the detected absence of a storage tube 74. Inventory statusis maintained in the control 240 and the sensor 230 provides a fail-safecheck in case the inventory is not correct in that the control 240 willnot direct the pick device 62 to pick from an empty location. Whencontrol 240 receives a signal from a sensor 230 indicating that apackage 16 was not detected on a gripper 130, the control may provide asignal to an operator that the package 16 was not detected. The control240 may also flag the order associated with the detected absence of thepackage 16 for separate processing to confirm that the order is faultyand, optionally, to correct the error in filling the order. The control240 may also be configured to stop operation of the dispensing system 10when a detected error will adversely affect operation of the dispensingsystem 10 to fill orders.

The control 240 may also be configured to optimize the picking ofpackages 16 from the storage module 60 and the transfer of the packages16 to the carriers 32. In particular, the control 240 may be configuredto monitor the order frequency of the medications/supplements and toassign locations for the storage tubes 74 in the bins 72 of the storagemodule 60 based on order frequency. For example, the control 240 mayassign locations for storage tubes 74 containing medications/supplementsthat have a relatively higher order frequency to be placed in bins 72that are located relatively lower in the storage units 66 and/or arepositioned relatively closer to the transfer stations 64 so that thedistance required to be traversed by the pick device 62 to retrievepackages 16 of high demand medications/supplements is minimized, therebydecreasing the time required to transfer packages 16 for the orders inthe queue supports 162. Accordingly, the particular locations of thestorage tubes 74 within the bins 72 of the storage module 60 can bedynamic and may be modified by the control 240, as may be desired forefficient processing of orders.

In another embodiment, the control 240 may be configured to track thedispensing of medications/supplements from the storage tubes 74 withinthe storage module and to provide signals to an operator when the supplyof packages 16 in a given storage tube 74 is becoming low. This allowsreplacement of the storage tubes 74 or, alternatively, replenishment ofthe packages 16 within the storage tubes 74, at convenient times. Thedispensing system 10 is also configured to facilitate replacement of thestorage tubes 74 or, alternatively, replenishment of the packages 16within the storage tubes 74, on-the-fly while the dispensing system 10is operating to fill orders. In particular, the configuration of thestorage module 60 facilitates access to the receiving ends 76 of thebins 72 for removal and replacement of storage tubes 74 while thedispensing system is operating to fill orders. In the event that thepick device 62 attempts to retrieve a package 16 from a storage tube 74when the storage tube 74 has been removed for replacement, the control240 receives a signal from sensor 99 associated with the bin 72 and maycontrol the pick device 62 to wait until the storage tube 74 has beenreplaced before attempting to retrieve the package 16.

While FIG. 1 illustrates the dispensing system 10 as having ahigh-demand module 12 and a low demand module 14 provided on only oneside of the conveyor 30, the dispensing system 10 may alternatively beconfigured with high-demand modules 12 and low-demand modules 14provided on both sides of the conveyor 30, to accommodate the quantityof medications/supplements and throughput requirements of the system, asmay be desired. In such a configuration, the high-demand modules 12 andlow demand modules 14 on both sides of the conveyor 30 are controlled bya common controller 240 and operate generally as described above and inU.S. patent application Ser. No. 12/559,630, however, the packages 16 ofmedications/supplements may be transferred to the carriers 32 movingalong the conveyor 32 from the high-demand modules 12 and low-demandmodules 14 on both sides of the conveyor 30.

While the present invention has been illustrated by the description ofone or more embodiments thereof, and while the embodiments have beendescribed in considerable detail, they are not intended to restrict orin any way limit the scope of the appended claims to such detail. Thevarious features described herein may be utilized alone or in anycombination. Additional advantages and modifications will readily appearto those skilled in the art. The invention in its broader aspects istherefore not limited to the specific details, representative apparatusand method and illustrative examples shown and described. Accordingly,departures may be made from such details without departing from thescope or spirit of the general inventive concept.

1. An automation apparatus for dispensing groups of individuallypackaged products, the apparatus comprising: a storage arrangementadapted to store a plurality of products each contained in an individualpackage, wherein the storage arrangement comprises a first module and asecond module, wherein the first module is adapted to store productshaving a first frequency demand threshold and the second module isadapted to store products having a second frequency demand thresholdthat is lower than the first frequency demand threshold; a plurality offixed first discharge assemblies adapted to move selected ones of theindividual packages from the first module of the storage arrangement; asecond discharge assembly comprising a moveable pick device, the seconddischarge assembly adapted to move selected ones of the individualpackages out of the second module of the storage arrangement; a transferstation adapted to receive and hold the individual packages selectedfrom the second discharge assembly; and a conveyor adapted to receivethe selected individual packages first from the first dischargeassemblies and then from the transfer station, wherein the plurality offirst discharge assemblies are configured to move the selected ones ofthe individual packages directly from the first module to the conveyor.2. The apparatus of claim 1, further comprising: a sensor to inspect theindividual packages; and a control device to verify that the individualpackages are correct.
 3. The apparatus of claim 1, wherein the storagearrangement further comprises: a plurality of storage tubes in both thefirst module and in the second module, each tube adapted to contain aplurality of one type of product in individual packages.
 4. Theapparatus of claim 3, wherein the storage tubes of the first module arearranged in a generally linear array and oriented generallyperpendicularly relative to a direction of travel of the conveyor andthe storage tubes of the second module are arranged in a two-dimensionalarray and oriented obliquely relative to the conveyor direction oftravel.
 5. The apparatus of claim 1, wherein the conveyor furthercomprises: a plurality of carriers each fixedly mounted relative to eachother and movable along a conveyor path, each carrier being adapted toreceive and hold a plurality of the individual packages in a lineararrangement.
 6. The apparatus of claim 1, wherein the pick device of thesecond discharge assembly further comprises at least one gripper movablefrom a first position for engaging and picking an individual package toat least a second position.
 7. The apparatus of claim 6, wherein thepick device of the second discharge assembly further comprises atransfer nest proximate the gripper, the transfer nest including atleast one slot for receiving one or more individual packages from thegripper, the transfer nest movable from a first position wherein theindividual packages can be received from the gripper, to a secondposition for delivering the individual packages to the transfer station.8. The apparatus of claim 1, wherein the transfer station is locatedbetween the second discharge assembly and the conveyor.
 9. The apparatusof claim 5, wherein the conveyor is adapted to receive blister packagesin a linear arrangement.
 10. A method of dispensing a selection ofindividually packaged products, the method comprising: moving a conveyoralong a conveyor path past a first storage module and a second storagemodule, wherein the first module is adapted to store products having afirst frequency demand threshold and the second module is adapted tostore products having a second frequency demand threshold that is lowerthan the first frequency demand threshold; moving a first subset of theselection of individually packaged products via one or more fixed firstdischarge assemblies directly onto the conveyor; retrieving a secondsubset of the selection of individually packaged products from thesecond storage module via a second discharge assembly comprising amoveable pick device; moving the retrieved second subset of theselection of individually packaged products into a transfer station;holding the second subset of the selection of individually packagedproducts at the transfer station; and moving the retrieved second subsetof the selection of individually packaged products onto the conveyor.11. The method of claim 10, further comprising: inspecting and verifyingthe individually packaged products during retrieval.
 12. The method ofclaim 10, wherein the first and second storage modules comprise aplurality of storage tubes, each tube adapted to contain a plurality ofone type of product in individual packages.
 13. The method of claim 12,wherein the storage tubes of the first module are arranged in agenerally linear array and oriented generally perpendicularly relativeto a direction of travel of the conveyor and the storage tubes of thesecond module are arranged in a two-dimensional array and orientedobliquely relative to the conveyor direction of travel.
 14. The methodof claim 10, wherein the conveyor comprises a plurality of carriers eachfixedly mounted and movable along a conveyor path, each carrier beingadapted to receive and hold a plurality of the individual packages in alinear arrangement.
 15. The method of claim 10, wherein the moveablepick device of the second discharge assembly further comprises atransfer nest, further comprising moving the transfer nest from a firstposition wherein the second subset of individual packages can bereceived after being picked from the second storage module, to a secondposition for delivering the second subset of individual package to thetransfer station.
 16. The method of claim 10, wherein the transferstation is located between the second discharge assembly and theconveyor.
 17. The method of claim 14, further comprising receiving andholding the selection of individually packaged products in a slot withinthe conveyor.
 18. The method of claim 14, wherein the individuallypackaged products are each contained in blister packages.
 19. The methodof claim 10, further comprising receiving and holding the selection ofindividually packaged products in a linear arrangement in the conveyor.